Rockwell Automation SA500 Series Bedienungsanleitung

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Instruction Manual

Distributed Power System

SA500 AC Power Modules

615055-1R (14 Amp)

615055-1S (28 Amp)

615055-1T (35 Amp)

615055-1V (48 Amp)

S-3018-1

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Throughout this manual, the following notes are used to alert you to safety considerations:

Important: Identifies information that is critical for successful application and understanding of the product.

The thick black bar shown on the left margin of this paragraph will be used throughout this manual to signify

new or revised text or figures.

!ATTENTION:Identifies information about practices or circumstances that can lead to personal

injury or death, property damage, or economic loss.

The information in this user’s manual is subject to change without notice.

AutoMax™ is a trademark of Rockwell Automation.

!ATTENTION:Only qualified personnel familiar with the construction and operation of this

equipment and the hazards involved should install, adjust, operate, or service this equipment.

Read and understand this manual and other applicable manuals in their entirety before

proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:Only qualified Rockwell personnel or other trained personnel who understand the

potential hazards involved may make modifications to the rack configuration, variable

configuration, and application tasks. Any modifications may result in uncontrolled machine

operation.Failuretoobservethisprecautioncouldresultindamagetoequipmentandbodilyinjury.

ATTENTION:The user must provide an external, hardwired emergency stop circuit outside of the

drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled

machine operation may result if this procedure is not followed. Failure to observe this precaution

could result in bodily injury.

ATTENTION:RegistersandbitsintheUDCmodulethataredescribedas“readonly”orfor“system

use only” must not be written to by the user. Writing to these registers and bits may result in

improper system operation. Failure to observe this precaution could result in bodily injury.

ATTENTION:For brushless motor applications, changing any resolver wiring, breaking the

resolver coupling, replacing the resolver, or replacing the motor and resolver for any reason

requires that the shaft alignment test be performed again. Resolver wiring changes always affect

shaft alignment. A resolver change and/or a new motor/resolver combination will affect the shaft

alignment.Impropershaftalignmentcancausemotoroverspeedwhenthemotorisstarted.Failure

to observe this precaution could result in bodily injury.

ATTENTION:The Power Module contains static-sensitive parts and assemblies. When not

installedinthe PowerModule,componentsshouldbe storedinanti-staticbags.Failuretoobserve

this precaution could result in damage to, or destruction of, the equipment.

ATTENTION:The user is responsible for conforming with all applicable local, national, and

international codes. Failure to observe this precaution could result in damage to, or destruction

of, the equipment.

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Table of Contents

CONTENTS

Chapter 1 Introduction

1.1 Distributed Power System (DPS) Overview ....................................................1-2

1.2 SA500 Drive Overview ....................................................................................1-3

1.3 Related Publications........................................................................................1-4

Chapter 2 Power Module Mechanical Description

2.1 LED Indicators.................................................................................................2-3

2.2 Power Module Faceplate Connectors .............................................................2-6

2.2.1 Fiber-Optic Ports...................................................................................2-7

2.2.2 Rail Ports...............................................................................................2-7

2.2.3 Resolver Feedback Connector..............................................................2-8

2.2.4 Drive I/O Connector ............................................................................2-10

Chapter 3 Power Module Electrical Description

3.1 Power-Up Routine ........................................................................................... 3-1

3.2 DC-to-DC Converter........................................................................................3-2

3.3 Resolver Interface ...........................................................................................3-2

Chapter 4 Installation Guidelines

4.1 Wiring and Grounding......................................................................................4-1

4.2 Power Module Installation ...............................................................................4-1

4.3 Fiber-Optic Connection....................................................................................4-6

4.4 Drive I/O Connections .....................................................................................4-6

4.5 Rail Port Connection........................................................................................4-8

4.6 Resolver Feedback Connection ......................................................................4-8

4.6.1 Resolver Input Connections................................................................4-10

4.6.1.1 Resolver Calibration..............................................................4-11

4.6.1.2 Resolver Alignment...............................................................4-12

4.6.1.3 Resolver Feedback Precautions...........................................4-13

4.6.2 Analog Input........................................................................................4-14

4.7 Constant Power Calibration...........................................................................4-14

4.8 Power Module Replacement .........................................................................4-17

Chapter 5 Diagnostics and Troubleshooting

5.1 Drive Faults (UDC Register 202/1202)............................................................5-1

5.2 Power Module Warnings (UDC Register 203/1203)........................................5-3

5.3 Power Module Failure......................................................................................5-4

Appendix A Technical Specifications...........................................................................................A-1

Appendix B Brushless Industrial Motor Data and Curves............................................................B-1

Appendix C Custom DC Bus Supplies.........................................................................................C-1

Appendix D UDC Register Cross-Reference ...............................................................................D-1

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SA500 Power Modules

Appendix E Status of Data in the AutoMax Rack After a

STOP_ALL Command or STOP_ALL Fault.............................................................E-1

Appendix F PMI Regulator Block Diagram.................................................................................. F-1

Appendix G Power Circuitry Block Diagram ................................................................................G-1

Appendix H Compliance with Electromagnetic Compatibility Standards.....................................H-1

Appendix I SA500 Power Module Output Current Overload Ratings...........................................I-1

Index ...........................................................................................................................Index-1

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Table of Contents

III

List of Figures

Figure 1.1 – SA500 Drive Hardware Configuration ..................................................1-2

Figure 2.1 – SA500 Power Module With Cover and Without Cover.........................2-2

Figure 2.2 – Power Module External Connectors.....................................................2-6

Figure 2.3 – Location of Rail Fuse on PMI Regulator PC Board..............................2-8

Figure 2.4 – Resolver Feedback Connector Pinout..................................................2-9

Figure 2.5 – Analog Input Circuit............................................................................2-10

Figure 2.6 – Drive I/O Connector Pinout.................................................................2-11

Figure 2.7 – Auxiliary Input Circuit..........................................................................2-11

Figure 2.8 – Run Permissive Input (RPI) Circuit.....................................................2-12

Figure 3.1 – Resolver Data Format (12-Bit Mode)....................................................3-2

Figure 3.2 – Resolver Data Format (14-Bit Mode)....................................................3-3

Figure 3.3 – External Strobe Input Circuit.................................................................3-3

Figure 3.4 – External Strobe Input Circuit Timing Diagram......................................3-4

Figure 4.1 – Power Module Mounting Dimensions...................................................4-3

Figure 4.2 – DC Bus Supply Wiring..........................................................................4-5

Figure 4.3 – Terminal Block Connections for Drive I/O ............................................4-7

Figure 4.4 – Terminal Block Connections for Resolver and Analog Input................4-9

Figure 4.5 – Typical Motor Operation in the Constant Torque and

Constant Power Regions....................................................................4-15

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SA500 Power Modules

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Table of Contents

List of Tables

Table 1.1 – SA500 Power Modules..........................................................................1-1

Table 1.2 – SA500 Documentation (Binder S-3002) ................................................1-4

Table 4.1 – Recommended Motor Wire Sizes..........................................................4-4

Table 4.2 – Rail I/O Instruction Manuals...................................................................4-8

Table 4.3 – Standard Resolver Connections..........................................................4-10

Table 4.4 – Recommended Resolver Cables.........................................................4-10

Table 4.5 – STATOR_IZ Tunable Values...............................................................4-16

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SA500 Power Modules

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Introduction

1-1

CHAPTER 1

Introduction

The AutoMax Distributed Power System SA500 AC Power Modules provide AC power

to, and control of, brushless motors and squirrel-cage induction motors from 1–15HP.

Each Power Module contains the Power Module Interface (PMI) Regulator printed

circuit board and the inverter used to convert DC power to AC power for the motor.

Depending upon their power requirements, up to six Power Modules can be

daisy-chained together and operated from one SA500 DC Bus Supply, which provides

the Power Modules a nominal 325 VDC input power. The DC Bus Supply is described

in instruction manual S-3017.

The SA500 Power Modules are available in four sizes with a range of current ratings to

complement the variety of motors available. See table 1.1 below.

Table 1.1 – SA500 Power Modules

Part Number Continuous Current

Rating (RMS)

Maximum Output

Current (RMS)

(0.5 seconds)1

1. Power Module output current overload rating charts are provided in Appendix I.

Power Module specifications are listed in Appendix A. Detailed speed-torque curves

and engineering data for SA500 motors are included in Appendix B.

Figure 1.1 shows a typical SA500 drive configuration.

615055-1R 14 A 17.5 A (125%)

615055-1S 28 A 35 A (125%)

615055-1T 35 A 70 A (200%)

615055-1V 48 A 106 A (220%)

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